The lecture introduced IPH – Institut für Integrierte Produktion Hannover gGmbH with its three fields of activity: forming technology, logistics and automation technology. Furthermore, research and consulting projects were discussed. In addition, the challenges regarding 8D report-based complaint management were presented as a major focus of current research.
quality management, complaint management, 8d report, data mining, text mining
For systematic processing of complaints the German Association of the Automotive Industry (VDA) recommends the 8D-method. However the method is commonly used in different industrial sectors, the lack of adequate means to assess complaint quality hinders correct and efficient complaint processing. The article presents the development of a set of indicators that addresses the above described problem. Implemented in a software prototype the indicators are determined in part by text mining algorithms as well as manually, e.g. by complaint process managers. Future research work will address the validation of the indicator set and its applicability in industry.
quality management, complaint management, 8d report, data mining, text mining
Manufacturing companies are now more than ever surrounded by a turbulent market environment. At the same time, the importance of networks and value-added networks. In theory and practice over and above the classical flexibility beyond mutability is seen as a precondition to be able to survive in this environment. Unfortunately, many companies are contrary to a number of technological and organizational change barriers in achieving versatile factory and network structures. This article gives an overview of the state of research and the development needs of the mutability of supply chains. In addition, requirements and potential solutions are presented, by what technologies and methods in the future the versatility can be improved and conversion barriers can be dismantled. The conversion-design of transport, storage and IT systems as well as planning and evaluation of the adaptability in supply chains are described mainly.
mutability, supply, factory and network structures, technological and organizational change barriers
Flashless precision forging is a special process of drop forging performed in closed dies. This process is distinguished by high quality and the ability to achieve a near net-shape part. Latest research results have shown that it is possible to forge a two-cylinder crankshaft without flash. This was realized using a multi-directional forging tool and a flashless precision forging operation. In this paper a new method for a three dimensional shrinking compensation is presented that facilitates the construction process
forging flashless precision near-netshape
Due to converting material flow in assembly areas inadequacies in logistics often lead to disturbances, bottlenecks and adaptation costs. In this contribution an approach is introduced, which systematizes the time-dynamic description of all processes for the assembly regarding relevant logistic and monetary targets. In this way it contributes to a comprehensive process and system understanding.
production planning and -steering, assembly throughput diagram, assembly controlling
The paper presents a method based on a semantic similarity search that supports employees in diagnosis and finding solutions. This semantic search methods have been modified and applied to find thematically similar service cases even when no identical symptoms are described. Using the method information about the machine, the customers and the service cases can be documented and made available to employees involved in the service process. The method was implemented in a software demonstrator.
semantic search, similarity search, service
The continuous improvement of production processes is a requirement to achieve and secure competitive advantages. This includes, among other things, to develop differentiating features faster than the competitors. In addition to technological innovations, organizational and logistical processes offer a significant potential for cost savings to small and medium enterprises (SMEs). For this reason enterprise resource planning (ERP) systems are getting more and more important. This paper describes eight steps for selecting the optimal ERP system.
erp systems, erp selection
This paper discusses the different characteristics used to describe XXL-products and, furthermore, presents fundamental aspects concerning the construction (e.g. principles, methods) of production systems. A survey of experts at XXL-producers is used to identify the most commonly implemented Lean-Production-Methods of production systems. The article presents the survey results and finally concludes with an outlook on further steps.
customizing, erp, potential savings, enterprise resource planning, individual adjustment, cost-benef
Large-scale products (XXL-products), such as bearing rings for wind turbines, pose special challenges to the production technology. For example, the continuous growth of product dimensions puts challenges on forming technologies as they reach their technical limits. Scaling effects, that occur when scaling up, can include physical limits for a further upscaling. These effects have only been studied for small scale production processes so far. The consideration of such effects in the large scale production offers the opportunity to exploit the potential of metal forming processes and improve the calculation forecasts.
xxl-products, forging, flowproperties, scaling factor, scaling effect, ring compression test
The trend for automated guided vehicles (AGV) is heading from a central control to decentralization. The term of agents is becoming more important in this context. Here, software agents are used that are not related to secret service or insurances. Software agents are autonomous units that independently decide on their own, with the use of predefined rules. Thus, a decentralized control is built. Current decentralized solutions are not continuously decentralized. Vehicles share a common topology or are controlled by a central station. Together with the "OFFIS - Institut für Informatik" researchers from the IPH develop an overall concept for a decentralized self-regulated AGV.
agv, decentralzied control, automated guided vehicles
On the one hand the precision forging involves substantial savings in material and process heat as well as in the reduction of the process steps. On the other hand, the tools are also much more exposed than the conventional forging. This leads to more rapid wear and a lower tool life of the tools. Within the framework of the subproject C4 of the Collaborative Research Center (SFB) 489 "process chain for the production of precision forged high performance components", therefore, a simulation-based approach will be developed, which allows the evaluation of new technical and organizational measures to improve the tool insert and thus supports a transfer into industrial practice.
precision forging, tool insert
Multi-directional forging enables flashless preforming for complex workpiece geometries by a cross-section formation and mass distribution in one forging stroke of the press. The process principle is based on a tool with multi-directional acting forming punches. In addition to the vertical forming by a punch a horizontal deformation is performed by horizontally arranged sliders. The drive of the sliders is performed by a redirection of the ram movement using wedges. The multi-directional forging has been studied and developed further over the past decade in a number of research projects. Starting with simple flashless, flat preforms for connecting rods made of steel, the technical feasibility of this method has been demonstrated. In subsequent steps, the principle has been transferred to crankshafts. As part of the Collaborative Research Centre 489, the crankshaft was broken down to a unit cell in order to investigate the fundamental transformation of the bearings and the crank webs. With this knowledge, forging sequences for simplified single and two-cylinder crankshafts were designed (without secondary form elements). Currently the forging sequence for a full two-cylinder crankshaft is designed with secondary design elements. The interaction of the mass distribution by cross-wedge rolling and multi-directional forging is analyzed. The flashless forging of two-cylinder crankshafts with such complicated geometries and corresponding necessary material flow is only possible using a multidirectional preforming. Finally, the applicability of the method to aluminum was investigated in the context of a DFG project – again based on a flat part long preforms. Here particularly clearly the limits of the process could be shown. Various forming directions were combined. With some of these combinations flash developed during the forming operation. Others have shown to be usable for a flashless preforming of complicated geometries.
multidirectional forging, flashless, preforming, cross-wedge rolling, connecting rod, crankshaft, st
8D reports often suffer from poor quality that could hinder effective troubleshooting within industrial supply and production processes. Thus, two research institutions developed a metric system that could help to detect poor quality 8D reports. Implemented in a software prototype the metric system can help to comprehensively improve complaint management processes.
quality management, complaint management, 8d report, data mining, text mining
The production machines in sheet metal forming are characterized by chaining of complex processes. Disruptions in a process can therefore shut down entire production lines and lead to high losses. Knowledge of disturbances and associated corrective actions in this case achieve a high degree of complexity, so that effective management and recording of this knowledge requires computer support.
sheet metal forming, experience recovery, equipment effectiveness
Function based structures for cost estimating. The complexity and the unique character of tool and mould constructions are the reasons why the calculation during the offer phase of the moulds and tools are using customer requirements and insufficient product information as a basis. For this purpose an increasing number of commercial software packages are used. Nevertheless, the support for the calculation is still inadequate. The IPH develops a method which allows a precise, transparent and with little effort achievable estimation for an offer on the basis of tool functions and the knowledge about already produced tools in a company.
function-based method, tender preparation, injection molding
The increasing complexity of factory planning tasks requires new methods and tools for accumulating planning stages. To make the process of factory planning for their clients more efficiently the IPH and RMA have developed in numerous successful projects and a joint as far as possible parallel action for the implementation of factory planning. Through constant exchange of information and coordination of the offices from both sides of methods and tools the efficiency of factory planning projects jointly implemented could be increased in terms of "power form". The basic idea is a parallel development of the factory of process and space perspective.
factory planning, complexity
To survive in the rivalry of competing supply chains in strong market dynamics, logistic measures of single companies are no longer sufficient. The reaction to disturbances needs to be aligned within the supply chain. Otherwise losses of efficiency result as increased inventory costs and reduced logistic performance. These losses are caused in early tiers of the supply chain. Due to the Bullwhip effect, they result in highly amplified inefficiencies throughout the complete supply chain. This article presents the development of a methodical support for synchronising the logistic reaction in supply chains. Therefore, reactions on disruptions and demand changes are determined and – according to their effect on logistic objectives – quantified. Cause-effect relationships of all processes within the supply chain (Source, Make and Deliver) are identified.
supply chain management, logistic reactivity
As a result of increasing globalization in procurement an increased competition exists for production companies. In the field of sheet metal forming companies will therefore be required to produce proper quality products with short delivery times at high punctuality at lowest possible production costs.
sheet metal forming, experience recovery, equipment effectiveness
In a current research project at IPH – Institut für Integrierte Produktion Hannover gGmbH and Laser Zentrum Hannover e. V. the knowledge of die failure mechanisms during the forming of aluminium will be extended. Aspects of the analysis are minimization, quantification and forecasting of adhesion. Furthermore it will be analysed in what way the tools, laser-dispersed with aluminium oxide, decrease the adhesion.
aluminium forging, wear, wear coatings
The German forging industry is under ever increasing pressure to develop innovative products at low prices. The design of logistic efficient forging processes regarding economic aspects is an opportunity for cost reduction. Thereby, sumultaneous consideration of technological interfaces as well as indirect processes (e.g. tool logistics) leads to a continuous process chain optimization. Logistic effects of resulting process changes have to be identified within a dynamic production controlling system in order zu improve the logistic performance.
logistical optimization, process chain optimisation, production planning and -steering
